Toyota Supra Repair Manual

Ma70 series

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Owner's manual (275 pages)

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Summary of Contents for Toyota Supra

Page 1 However, it should be noted that the front fenders of all TOYOTA models are bolted on and re- quire no welding. Body construction will sometimes differ depending on specifica- tions and country of destination.
Page 2: How To Use This Manual
IN-2 INTRODUCTION HOW TO USE THIS MANUAL Each repair method description provided in Section RE of this manual comprises two pages, divided into 2 blocks (REMOVAL AND INSTALLATION) and includes illustrations to facilitate body repair. RE−26 BODY PANEL REPLACEMENT−Rear Body Components QUARTER PANEL (CUT) REMOVAL Cut and Join Location...
Page 3: Installation Guide
INTRODUCTION IN-3 BODY PANEL REPLACEMENT−Rear Body Components RE−27 INSTALLATION Butt Weld Butt Weld Body Sealer Braze Body Sealer About 5 mm 0.20 Temporarily installing the new part and check the fit of Before temporarily installing the new part, apply the front door, luggage compartment door and rear body sealer to the wheel arch portion.
Page 4 IN-4 INTRODUCTION SYMBOLS The following symbols are used in the welding Diagrams in Section RE of this manual to indicate cutting areas and the types of weld required. MEANING ILLUSTRATION SYMBOLS SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN−5)
Page 5 INTRODUCTION IN-5 Illustration of Weld Point Symbols EXAMPLE: INSTALLATION REMOVAL Weld points Weld points Weld method and panel position Remove weld point and panel position SYMBOL MEANING ILLUSTRATION SYMBOL MEANING ILLUSTRATION Remove Weld Points Spot Weld (Outside) Mig Plug Weld (Middle) (Inside) Spot MIG...
Page 6: General Repair Instructions
IN-6 INTRODUCTION GENERAL REPAIR INSTRUCTIONS Work Precautions SAFETY VEHICLE PROTECTION SAFETY Never stand in direct When welding, protect the Before performing repair work, check painted surfaces, windows, line with the chain when for fuel leaks. If a leak is found, be sure seats and carpet with heat−...
Page 7 INTRODUCTION IN-7 Proper and Efficient Work Procedures REMOVAL PRE−REMOVAL MEASURING REMOVAL. OF ADJACENT COMPONENTS NO. OF SPOT WELDS Make a note of the Before removal or cutting opera- When removing adjacent components, apply tions, take measurements in ac- protective tape to the surrounding body and number of spot welds for later reference.
Page 8 IN-8 INTRODUCTION INSTALLATION PRE−WELDING MEASUREMENTS WELDING PRECAUTIONS POST−WELDING REFINISH- Always take measurements before The number of welding spots installing underbody or engine com- Always check the welded should be as follows. ponents to insure correct assembly. spots to insure they are Spot weld: 1.3 x No.
Page 9 INTRODUCTION IN-9 PREPARATION FOR INSTALLATION SPOT WELD POINTS APPLICATION OF WELD−THROUGH PRIMER When welding panels with a For treatment combined thickness of over 3 against corrosion, mm (0.12 in.), use a MIG remove the paint (Metal Inert Gas) welder for from the portion of plug welding.
Page 10 IN-10 INTRODUCTION ANTI−CORROSIVE TREATMENT When replacing body panels, always apply body sealer, anti−rust treatment or undercoating according to the requirements of your country. CHASSIS RUST−PROOFING BODY SEALER Anti−rust treatment for weld- Apply body sealer to the ing spots or inside brazed required areas.
Page 11 INTRODUCTION IN-11 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front ..Center of front suspension crossmember Rear ..Center of differential carrier PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand .
Page 12 IN-12 INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. Assy, assy Assembly, assembly Sub−assy Sub−assembly Except Inch Independent Rear Suspension 4−link 4−link Rear Suspension Metal Inert Gas Model Year Operation Spot Weld (Resistance Spot Weld) With Without Front...
Page 13 TE-2 TOOLS AND EQUIPMENT MEASURING INSTRUMENTS For measuring body dimensions Tracking Gauge When 3 or 4 are used together, measure- ments of twists, bends or warps in the body and frame are possible. Frame Centering Gauge SEPARATING TOOLS For separating spot welds and making holes in the body.
Page 14 TOOLS AND EQUIPMENT TE-3 SEPARATING TOOLS (Cont’d) For rough cutting and rough flattening of panels. Air−powered Chisel For rough cutting of panels. Panel Cutter For separating spot welds. Flat Chisel For rough flattening in hard−to−reach areas. Hammer Tool For rough cutting of pillars, rocker panels, etc.
Page 15 TE-4 TOOLS AND EQUIPMENT INSTALLATION ASSISTANCE TOOLS For temporary installation of panels and holding of portions to be welded. Vise Grip Wrench For making flanges in overlapping panels. Flanging Tool For hemming door outer panels, etc. Hemming Tool For making holes for MIG plug welding.
Page 16 TOOLS AND EQUIPMENT TE-5 WELDING INSTRUMENTS For panel welding. MIG Welder (Metal Inert Gas) For panel welding. Spot Welder For rough cutting of panels, members, etc. Gas Welder Torch Gas Cutter Torch For soldering and peeling of paint. Acetylene Gas Torch For straightening distorted panels.
Page 17 TE-6 TOOLS AND EQUIPMENT LIGHT BODY REPAIR TOOLS For straightening lightly damaged panels. Body Pullers GRINDING AND POLISHING TOOLS For grinding plug welds, butt welds and door hems. Air−powered Disc Grinder For grinding plug welds, butt welds and door hems. Electric−...
Page 18 TOOLS AND EQUIPMENT TE-7 GRINDING AND POLISHING TOOLS (Cont’d) For rough polishing of panel putty. Straight−line Sander For removing putty over a wide area, re- surfacing and refinishing. Air−powered Orbital Sander For peeling paint. Air−powered Disc Sander For paint removal. File Holder For correction of soldering spots and resurfacing of panels.
Page 19: General Information
DI-2 BODY DIMENSIONS GENERAL INFORMATION Three−dimensional Center−to−center distance straight−line distance BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (Three−dimensional distance) S Straight−line distance between the centers of two measuring points. (Two−dimensional distance) Two−dimensional Center−to−center distance Horizontal distance in S Horizontal distance in forward/rearward between forward/rearward the centers of two measuring points.
Page 20 BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT mm (in.) Symbol Nomenclature Hole dia. A, a 8 (0.31) Front fender installation nut−front B, b Front spring support hole−rear 11 (0.43) C, c Front fender installation nut−rear 8 (0.31) Cowl top panel center mark E, e 15 (0.59) Front side member standard hole...
Page 21 BODY DIMENSIONS DI-3 LUGGAGE COMPARTMENT X, x Point Front mm (in.) Symbol Nomenclature Hole dia. Back door opening frame center mark 2 (0.08) W, w Rear suspension spring support hole−inner 9 (0.35) X, x Rear floor pan bumper installation hole−front BO1790 40 (1.57)
Page 22 Wheel base 2,595 (102.17) Imaginary Standard line mm (in) Symbol Nomenclature Hole dia. Symbol Nomenclature Hole dia Front floor No. 2 reinforcement standard hole 10 (0.39) 15 (0.59) Front side member bumper front installation hole−Lower Suspension member front installation hole−outer 19 (0.75) R, r Front side member bumper front installation hole−Lower...
Page 23 CN-2 BODY PANEL CONSTRUCTION STANDARD BODY MARKS LIFTBACK 0.08 0.28 φ 0.39 Center Mark Assembly Mark Center Mark φ Center Mark Assembly Mark Assembly Mark φ φ φ Assembly Mark Assembly Mark φ...
Page 24 BODY PANEL CONSTRUCTION CN-3 HIGH−STRENGTH STEEL (HSS) PARTS Generally, High−Strength Steel (HSS) is that which has an intensity value of at least 35 kg f/mm , and distinguished from mild steel. The handling of HSS is the same as for mild steel, but the following should be observed. Panel Hammering;...
Page 25 RE-2 BODY PANEL REPLACEMENT FRONT CROSSMEMBER (ASSY) REMOVAL...
Page 26 BODY PANEL REPLACEMENT RE-3 INSTALLATION Temporarily installing the new part and measure each part in accordance with the body dimen- sion diagram.
Page 27 RE-4 BODY PANEL REPLACEMENT RADIATOR SUPPORT (ASSY) REMOVAL Cut the weld points from the back side.
Page 28 BODY PANEL REPLACEMENT RE-5 INSTALLATION Assembly Mark Temporarily install the new part with the assembly mark and measure each part in accordance with the body dimension diagram.
Page 29 RE-6 BODY PANEL REPLACEMENT RADIATOR UPPER SUPPORT (ASSY) REMOVAL...
Page 30 BODY PANEL REPLACEMENT RE-7 INSTALLATION Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram. NOTE: Install the new panel with the hood lock support.
Page 31 RE-8 BODY PANEL REPLACEMENT FRONT FENDER APRON (ASSY) REMOVAL...
Page 32 BODY PANEL REPLACEMENT RE-9 INSTALLATION Assembly Mark Determine the installation position of the new part by the assembly mark. Measurements must be accurate with the body dimension diagram, as this effects the front wheel alignment. NOTE: The position of the front spring support hole is very important Check the fit of the front fender and hood.
Page 33 RE-10 BODY PANEL REPLACEMENT FRONT FENDER APRON (CUT−H) REMOVAL Rough Cut After removing the spot welds, rough cut the front fender apron shown above.
Page 34 BODY PANEL REPLACEMENT RE-11 INSTALLATION Cut for supply part Cut Location Cut Location Cut the supply part shown above.
Page 35 RE-12 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REMOVAL...
Page 36 BODY PANEL REPLACEMENT RE-13 INSTALLATION Assembly Mark Front Side Member Plate Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram. NOTE: Make sure each measurement is correct, as this part effects the front wheel alignment.
Page 37 RE-14 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (CUT−P) REMOVAL φ Standard Hole (15 Cut Location Cut Location φ Standard Hole (15 60 mm 20 mm NOTE: Be careful not to damage the reinforcement when cutting the side member. [USA and Canada] [Ex.
Page 38 BODY PANEL REPLACEMENT RE-15 INSTALLATION Cut for supply part Remove the remaining reinforcement from the supply part. Cut Location 70 mm Cut Location Reinforcement Reinforcement [USA and Canada] [Ex. USA and Canada] 20 mm 2.76 [USA and Canada] Butt Weld Butt Weld [Ex.
Page 39 RE-16 BODY PANEL REPLACEMENT COWL TOP SIDE PANEL (ASSY) REMOVAL Cut with disc sander etc.
Page 40 BODY PANEL REPLACEMENT RE-17 INSTALLATION Assembly Mark Assembly Mark Tack Weld (20 mm each) 0.79 Determine the installation position of the new part by the assembly mark. Temporarily installing the new part and measure each part in accordance with the body dimen- sion diagram.
Page 41 RE-18 BODY PANEL REPLACEMENT FRONT BODY PILLAR (CUT) REMOVAL 150 mm or more [Cut and Join Location] Cut and Join Location Cut With Disc Sander etc. Cut and join the front body pillar at the location shown above. 5.91 NOTE: As shown above, cut and join the front body pillar outer and inner panels at a position shifted about 50 mm (1.97 in.).
Page 42 BODY PANEL REPLACEMENT RE-19 INSTALLATION Butt Weld [Reference] (mm) Tack Weld (20 mm each) Temporarily install the new part and check the fit of the front door, front fender, hood and wind- 0.79 shield glass. 31.10 31.14 37.24 1,162 45.75 55.20 1,402 55.39...
Page 43 RE-20 BODY PANEL REPLACEMENT OUTER ROCKER PANEL (CUT) REMOVAL 140 mm Cut and Join Location [Cut and Join Location] 5.51 Cut and join the outer panel at the area as show above.
Page 44 BODY PANEL REPLACEMENT RE-21 INSTALLATION Butt Weld Temporarily install the new panel and check the fit for the front door and front fender. There will be less warp if the cut edge (30 − 40 mm or 1.18 − 1.57 in.) is adhered to the match- ing part before welding.
Page 45 RE-22 BODY PANEL REPLACEMENT ROOF PANEL (ASSY) REMOVAL Arc Brazing (both sides) Braze (both sides) Braze (both sides) Heat the brazed area of the front pillar and scrape off the brazing with a wire brush. NOTE: Be careful not to overheat the pillar. Cut off the roof panel tip at the quarter panel are brazing connection with a cut grinder.
Page 46 BODY PANEL REPLACEMENT RE-23 INSTALLATION Body Sealer (6 points) Braze (both sides) Body Sealer (8 points) Braze (both sides) Before temporarily installing the new part, Braze the front body pillar connection. apply body sealer to the windshield header NOTE: Before performing these operations, panel, roof panel center reinforcement and place a wet rag on the roof panel to protect it back window opening frame.
Page 47 RE-24 BODY PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ASSY) REMOVAL Hemming Location Heat slightly (USA, Canada, Saudi Arabia and Australia) Disc Sander Grind out the hemming location, and remove the outer panel. Slightly heating the outer panel will soften the sealer and make removal easier.
Page 48 BODY PANEL REPLACEMENT RE-25 INSTALLATION Assembly Mark Assembly Mark About 10 mm Do not close the Body Sealer (6 points) Body Sealer drain hole. (USA, Canada, Saudi Arabia and Australia) Cloth Tape ° Hemming Tool 0.39 Before temporarily installing the new part, coat Bend the flange hem approx.
Page 49 RE-26 BODY PANEL REPLACEMENT QUARTER PANEL (CUT) REMOVAL Cut and Join Location Cut and Join Location 200 mm 80 mm [Cut and Join Location] Front Braze Rear Cut and join the quarter panel as shown above. 3.43 7.87...
Page 50 BODY PANEL REPLACEMENT RE-27 INSTALLATION Butt Weld Butt Weld Body Sealer Braze Body Sealer About 5 mm 0.20 Before temporarily installing the new part, Temporarily install the new part and check the fit apply body sealer to the wheel arch portion. of the front door, luggage compartment door and rear combination lamp.
Page 51 RE-28 BODY PANEL REPLACEMENT QUARTER PANEL (CUT−P) REMOVAL About 335 mm Cut and Joint Location Cut and Joint Location * This section is a cut and join location only. Refer to RE−26 for weld points. Cut on the line shown above.
Page 52 BODY PANEL REPLACEMENT RE-29 INSTALLATION Butt Weld Body Sealer After butt welding, apply body sealer Butt Weld Body Sealer About 5 mm * This section is a cut and join location only. Refer to RE−27 for weld points. Before cutting the overlap areas, check the fit For other sealing points, refer to section SU.
Page 53 RE-30 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY) REMOVAL Braze (both sides) (both sides) (both sides)
Page 54 BODY PANEL REPLACEMENT RE-31 INSTALLATION Braze (both sides) (both sides) (both sides) Temporarily install the new part and check the fit of the back door and rear combination lamp.
Page 55 RE-32 BODY PANEL REPLACEMENT QUARTER WHEEL HOUSING OUTER PANEL (ASSY) REMOVAL Roof Side Inner to Wheel Housing Brace Before removing the quarter wheel housing out- er panel, remove the roof side inner to wheel housing brace.
Page 56 BODY PANEL REPLACEMENT RE-33 INSTALLATION Assembly Mark Assembly Mark Determine the position of the new part by the assembly marks of the inner and outer panels. Before welding the new part, temporarily install the quarter panel and check the fit.
Page 57 RE-34 BODY PANEL REPLACEMENT REAR FLOOR PAN (CUT) REMOVAL Cut Location (RH) (LH) Cut and join the rear floor pan shown above. Avoid the rear floor side member. Since each bracket is supplied separated, remove the brackets if reusing.
Page 58 BODY PANEL REPLACEMENT RE-35 INSTALLATION Cut Locations Plug Weld Adhere New Part Body Sealer Cut the new panel shown above. NOTE: Be sure the portion to be welded are align and not loose. Match the bracket to the new part location Coat the overlapping opening portion from the (dent marks) and install.
Page 59 RE-36 BODY PANEL REPLACEMENT REAR FLOOR SIDE MEMBER (ASSY) REMOVAL Before removing the rear floor side member, remove the rear floor pan.
Page 60 BODY PANEL REPLACEMENT RE-37 INSTALLATION Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram.
Page 61 RE-38 BODY PANEL REPLACEMENT CENTER FLOOR SIDE MEMBER (ASSY) REMOVAL...
Page 62 BODY PANEL REPLACEMENT RE-39 INSTALLATION Differential Support Member Mounting Reinforcement Quarter Wheel Housing No.1 Gusset Flexible Hose Bracket Temporarily install the new part and measure each part in accordance with the body dimen- sion diagram.
Page 63 RE-40 BODY PANEL REPLACEMENT CENTER FLOOR NO. 2 CROSSMEMBER (ASSY) REMOVAL...
Page 64 BODY PANEL REPLACEMENT RE-41 INSTALLATION...
Page 65 PL-2 PART LISTS 53301 55748A 55101 53385A (RH) 53899B 55713A (RH) 53386A (LH) 55714A (LH) 53701 55701 53723A (RH) 53724A (LH) 53801 53205 53287B (RH) 53288B (LH) 53202 53802 53257 53633 53258 53702 53291C 53203 53209 53932 53291C 57161 Code Part Name Code Part Name...
Page 66 PART LISTS PL-3 61747 (RH) 61625E 61675B 61748C (LH) 61211 61547 61766B 61619A 61631A (RH) 61261 61707 61632A (LH) 61773A 61103 61231 61633A (RH) 61347A 61634A (LH) 61768B 61515A 61641B (RH) 61611 616428 (LH) 61345B 61626E 61767B 61367 61708 61548 61774A 61619A 61388A...
Page 67 PL-4 PART LISTS 58307 58364B 58183 58305 58364B 58183 58102A 58311E 58313F 58311 58109A 58208 58193 57465A 58101A 57457C 58314F 57656A 57468A 58367 58173 58346 58275C 57673 7466A 58142 58212C 57469A 58173 58111 58264B 58207F 57467A 58101F 58101F 58208F 58142 58029A 57463 57405A...
Page 68 PART LISTS PL-5 Code Part Name Code Part Name Flexible Hose Bracket 51681 57656A Exhaust Pipe Mounting No. 1 Bracket 57673 Rear Seat Back Hinge Mounting Bracket 57043 Front Side Member Rear Reinforcement 57044 57737 Differential Support Member Mounting 57747 Reinforcement 57071 Torque Rod Rear Box Sub−Assy...
Page 69 PL-6 PART LISTS 63111 63105A 63104 63102A 67005 61111 (RH) 61112 (LH) 67001 (RH) 67002 (LH) Part Name Code Code Part Name Windshield Header Panel Sub−Assy 63102A 67001 Front Door Panel Sub−Assy 67002 Roof Panel Center Reinforcement Sub−Assy 63104 Back Door Panel Sub−Assy 67005 63105A Back Door Opening Frame Sub−Assy...
Page 70 PP-2 PLASTIC BODY PARTS HANDLING PRECAUTIONS The repair procedure for plastic body parts must conform with the type of plastic material. Plastic body parts are identified by the codes in the following chart. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint- ing, etc.), consideration must given to the property of the plastic.
Page 71 PLASTIC BODY PARTS PP-3 Heat * Resisting Material Resistance To Code Notes Temperature Name Alcohol or Gasoline ° ° Alcohol and gasoline are Most solvents are Polypropylene (176) harmless. harmless. Gasoline is harmless if Modified applied only for quick Polyphenylene Alcohol is harmless.
Page 72 PP-4 PLASTIC BODY PARTS LOCATION OF PLASTIC BODY PARTS Fuel Tank Filler Protector (PE) Roof Headlining Safety Pad (PVC/PUR) (PVC/PUR) Quarter Ventilation Washer Nozzle (PA) Louver (ABS) Rear Spoiler (SMC) Front Facia Cover (PUR) Fan Shroud (PP) Washer Jar (PP) *1 Rear Side Marker Lamp (PMMA/ ABS)
Page 73 PLASTIC BODY PARTS PP-5 Front Body Pillar Garnish (PUR) Roof Side Rail Front Garnish (PVC) Roof Side Trim Garnish (ABS/PVC) Font Door Trim Board (PVC/PP) Roof Headlining Rear Trim (PVC) Quarter Inside Trim Board Speaker Door Grill (ABS) (PVC/PP) Cowl Side Trim Board (PP) Back Door Trim Board (PP) Headlight Door (AAS)
Page 74 PP-6 PLASTIC BODY PARTS Deck Trim Side Jack Cover (PP) Deck Side Trim Panel (PP) Cooler Unit (PP) Rear Speaker Grill (PP/ABS) Heater Unit (PP) Heater Blower (PP) Deck Trim Rear Cover (PP) Deck Trim Side Service Hole Cover (PP) Font Fender Mud Rear Combination Guard (PUR)
Page 75 SU-2 BODY PANEL SEALING AND UNDERCOATING BODY PANEL SEALING AREAS For water−proofing and anti−corrosion measures, always apply body sealer to the body panel seams and hems of the doors, hood, etc. NOTE: Prior to applying body sealer, clean the area with a rag soaked in white gasoline. If weld−through primer was used, first wipe off any excess with thinner, and coat with anti−...
Page 76 BODY PANEL SEALING AND UNDERCOATING SU-3 After installing the plug hole, apply sealer. Flat Surfacing...
Page 77 SU-4 BODY PANEL SEALING AND UNDERCOATING Flat Surfacing...
Page 78 BODY PANEL SEALING AND UNDERCOATING SU-5 Hood Front Door Panel Back Door Panel Do not close the drain hole. Flat surfacing Fuel Inlet Box Fuel Inlet Box Cover...
Page 79 SU-6 BODY PANEL SEALING AND UNDERCOATING BODY PANEL UNDERCOATING AREAS To prevent corrosion and protect the body from damage by flying stones, always apply undercoating to the welded seams and wheel housings after chassis, under body or panel repair. NOTE: First wipe off any dirt, grease or oil with white gasoline.

Toyota Supra Repair Manual

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Summary of Contents for Toyota Supra

Page 2: How To Use This Manual

Page 3: Installation Guide

Page 6: General Repair Instructions

Page 19: General Information

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